How to start your own production of foam rubber? Business plans for the production of products by pouring PPU We analyze the sales market

When choosing the direction of the future business, it is better to give preference to the production of those products that are in high consumer demand, regardless of the season and the state of the economy in the country. Here we include the production of foam rubber. Investments in launching an enterprise will be impressive, but with a competent approach, investments will pay off very quickly. Study the issue thoroughly to take into account all the nuances.

How to open a plant for the production of foam rubber in Russia?

Our business valuation:

Starting investments - from 1,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 6/10.

Business Advantages and Disadvantages

Foam rubber (polyurethane foam) has been used in everyday life and for industrial purposes for many decades. Despite the appearance on the market of fundamentally new materials with similar properties, foam rubber does not lose its popularity among consumers. This will be the main advantage for the businessman - wholesale clients can always be found!

Foam rubber is a soft, elastic material used in furniture and clothing production. But these areas of application are not limited - the manufacture soft toys, transportation of fragile goods.

The production and sale of foam rubber in Russia is not very developed, which gives future entrepreneurs good chances for a quick payback of the project. If you supply quality products to the market, you can beat any competition.

As for the shortcomings, the main one is the difficulty with the equipment of the room. The production of foam rubber is considered harmful, so powerful ventilation equipment must be installed in the workshops, which will entail financial costs. You will need to obtain permission from the regulatory authorities to operate. The enterprise must strictly observe working conditions and control the amount of harmful emissions into the atmosphere - frequent inspections of sanitary, environmental and fire services cannot be avoided.

It is better to start a mini plant in early spring. It was during this period that all furniture factories “activated” - an active purchase of raw materials began. So you will quickly find buyers for your products.

Legal registration of the enterprise

It will take at least 3 months to collect all documents and permits for registration of the enterprise. Much faster, you can arrange everything with the help of a lawyer.

OKVED is suitable for the enterprise to be opened: 24.70 (Production of artificial and synthetic fibers).

It is better to formalize the industrial production of foam rubber in the form of an LLC - it is easier to find buyers of finished products and suppliers of raw materials. You will receive a permit to conduct activities only after the premises are found and prepared, contracts are concluded with suppliers of raw materials, and certificates of quality of finished products are received.

Business premises

Place the production of furniture foam rubber in a free room on the outskirts of the city. Firstly, renting real estate here is cheaper, and secondly, security requirements environment won't be that high. This will greatly facilitate the process of starting an enterprise.

To organize a production workshop, storage facilities and service rooms will require at least 200 m 2. If a large capacity plant is planned, look for a larger building.

In addition to ensuring good ventilation in the workshop and the availability of treatment facilities, other requirements are imposed on the premises found:

To accommodate the equipment for the production of foam rubber, the height of the ceilings must be at least 3 m.
The temperature in the shop for pouring the foamed mass into molds is not lower than 18 ˚C.
The presence of electrical wiring for 380 V.

If free space does not allow, the company's office can be located in another place - where it will be convenient for customers to get to. But this is an extra cost for the organization of activities.

foam production technology

Raw materials for foam rubber are polyol and diisocyanates. These substances, if the technology is not followed, can be harmful to the human body. But if good ventilation is provided in the workshop, and only high-quality “ingredients” are processed, there will be no chemical poisoning of personnel and harmful emissions into the atmosphere. The specific ratio of components will depend on the type of foam produced. There are several of them:

Standard (ST). For production, 1 type of polyol is used. The stiffness of the resulting material is determined by its density.
Increased rigidity (EL). In the foam manufacturing process, several types of polyol are used to give the finished product a special rigidity. Ideally, it is this material that should be used in the manufacture of furniture. But because of the high price, many furniture makers refuse it.
Hard (HL). The manufacturing technology differs little from the previous method. But the final price of the product, due to cheaper raw materials, is much lower.
Highly elastic (HR). The material is made on the basis of special grades of polyol. After the raw materials pass through the equipment, foam rubber blocks are obtained.
Soft (HS). It is a soft, resilient material used to make some types of upholstered furniture and pillows. In this case, components for foam rubber are used, which give the material greater porosity.

There are also special brands of foam rubber, which later go to the manufacture of sponges for washing dishes, self-adhesive insulating strips. There is foam rubber, which has soundproofing properties. Prices for products in this case will be slightly higher.

It is better to immediately negotiate with suppliers about wholesale deliveries raw materials - this will ensure the uninterrupted operation of production equipment.

The production technology of foam rubber depends on the method - continuous and periodic. To choose the appropriate option, it is necessary to evaluate the planned capacity of the plant, the raw materials used. It is advisable for small enterprises to introduce a periodic method in production. The "averaged" technological scheme for the manufacture of foam rubber looks like this:

Preparation of raw materials - acceptance, dosing.
Mixing liquid components
Mass foaming.
Bookmarking the mass in special forms with folding walls.
Form cooling.
After 3 days, the foam rubber is cut into sheets of the desired size.

In the process of manufacturing the finished material, waste is generated. They can either be sold to consumers (the same furniture factories, for example), or you can plan the production of recycled foam rubber. The technology involves foaming foam rubber chips and scraps with a special glue, followed by pressing the mass under pressure. Finished products have excellent quality characteristics - increased strength, sound insulation, durability. It is in this way that the production of acoustic foam rubber and mats for gyms is carried out. So you will find more buyers interested in your products.

Secondary foam rubber is available in several grades - BB-60, BB-80, BB-100, BB-120, BB-140, BB-160. Materials differ in properties and physico-chemical parameters.

Purchase of technological equipment

The simplest line for the production of foam rubber

The foam rubber production line is the most expensive budget item. For the manufacture will require the following machines:

raw material grinding machine,
dosing tanks,
frother,
thermal Camera,
forms,
packing machine,
waste shredder machine.

It is difficult to assemble a line from separate devices. It makes sense for novice entrepreneurs to buy a line that is already ready for work.

The price of equipment for the production of foam rubber will depend on the capacity of the machines. The mini-shop can be equipped with a low-productivity line that produces up to 12 cm 3 of finished products per shift. This will cost 400,000 rubles. But you can buy equipment for foam rubber of greater power (up to 50 m 3) by spending at least 2,000,000 rubles. To the cost of purchasing devices, add the seller's services for their commissioning. All manipulations to set up the line can be done on your own, but you need to know the specifics of its work well.

You can save money by buying used equipment. The price of used machines is much lower. And if you find a reliable seller, the purchased line will last a long time.

Profitability of the planned business

All costs for the foam rubber machine will begin to pay off when contracts are concluded with regular customers of finished products. Depending on what type of material is produced within the walls of the workshop, offer the goods:

furniture factories;
factories of toys and household products;
enterprises producing sports equipment;
mattress factories.

Offering consumers special types of products, such as foam rubber with an adhesive layer, can attract more customers. If this cannot be done at the beginning of the formation of the enterprise, be sure to think about developing the business. It is important to constantly improve production methods.

The payback period depends on the initial costs. If we consider the minimum, then the organization of the workshop will take 1,000,000 rubles. This will include funds to buy a foam rubber cutting machine and other equipment, prepare the premises for work, and formalize the enterprise. You will open a high-performance plant if you have at least 3,000,000 rubles.

Profit, based on data on expenses and income from sales, can be calculated independently. Standard foam rubber for upholstered furniture costs at least 140 rubles per sheet measuring 20/125/2500 mm. The price of a material with improved properties is much higher - up to 500 rubles per sheet. At the same time, the cost of production is at least 30% lower, which will show good profitability in the future.

Organization of the production of polyurethane foam boards of the following dimensions and densities:

For floor insulation - density 60 kg / m3, dimensions 1500x1000x150mm and 1500x1000x130mm.
For wall insulation - density 35 kg / m3, dimensions 1200x600x50mm.

Please note that the production of polyurethane foam boards with a thickness of more than 70 mm is associated with a number of technological difficulties, namely, a significant increase in the holding time of the product in the mold (more than 1 hour), respectively, a decrease in the formwork turnover, and an increase in the production time. It will also require the use of raw materials with a high start time (up to 3 minutes), as a result of which deterioration of the foam structure is possible.

If it is necessary to obtain plates of a given thickness, we recommend that you glue together three plates. For these purposes, a special polyurethane adhesive is used, for example, from KIMP (Vladimir).

In connection with the foregoing, we recommend using a form of one standard size 1500x1000x50mm (provided that you are ready to go for replacing the 1200x600x50 slab with 1500x1000x50). To obtain a plate with a thickness of 130 mm, it is necessary to glue two plates with a thickness of 40 mm and one 50 mm. It is possible to obtain a product with a thickness of 40 mm in the desired form, if an insert is laid on its bottom - a sheet of metal 10 mm thick, i.e. raise the bottom.

The calculations below are based on the production of slabs 1500x1000x150 in a volume of 225 cubic meters and 1500x1000x130 in a volume of 225 cubic meters using molds 1500x1000x50 and liners.

1. Equipment model selection

The essence of the technological process is that two liquid components (isocyanate and polyol) are mixed and fed into a certain form. After some time, the composition "starts", i.e. there is a noticeable increase in volume (tens of times), a change in color (whitening). As a rule, the "start time" is 1825 seconds. The time during which the liquid is injected into the formwork is called the "injection time".

A prerequisite for obtaining a normal product is to stop the injection of the composition "A" and "B" before the start. It is forbidden to continue injection into the mold if there is already an increase in the volume of foam mass. In this case, there is a real danger that it will not be possible to close the mold, and the product will be damaged (both the internal structure and the geometric contours).

One of the conditions for obtaining high-quality products when pouring polyurethane foam is to provide for a minimum period of time (less than the start time of the composition) the entire mass of the mixed composition required to fill a given volume is fed into the mold or cavity. If the same product can be obtained for injection, for example, 7.5 s and 15 s, provided that in the first case the productivity is twice as high, the first option should be chosen.

FOAM20P20UM4, with a capacity of 1 to 6 liters per minute (with the ratio of components "A" and "B" as 1 to 1);
FOAM20P75UM, with a capacity of 8 to 24 liters per minute (with the ratio of components "A" and "B" as 1 to 1).

The density of the polyol is typically 1.04 kg/m3, the density of the isocyanate is 1.24 kg/m3. Then, with the weight ratio of components "A" and "B" corresponding to 1 to 1, the density of the mixture "A" + "B" (in the liquid state, before the start) is 1.14 kg/m3. That. the maximum possible mass of the product obtained at various pumping stations is:

2.28 kg for PENA20P20UM4 with a capacity of 6 liters per minute (with the ratio of components "A" and "B" as 1 to 1);
9.12 kg for PENA20P75UM at a capacity of 24 liters per minute (with the ratio of components "A" and "B" as 1 to 1).
The normal density of the foam directly in the product is from 40 to 60 kg/m3.
The volume of one plate is: 1.5 x 1 x 0.05 = 0.075 m3.
With a product density of 40 kg / m3, the mass of the plate will be: 0.075 x 40 = 3 kg.
With a product density of 60 kg / m3, the mass of the plate will be: 0.075 x 60 = 4.5 kg.
Thus, a filling machine based on the PENA-20P75UM pumping station should be used.

2. List and cost of the main equipment

2.1. Pumping station FOAM-20P75UM, capacity from 8 to 24l/min, has dimensions 1250x650x1000mm and weight 180kg. Motor power 2.2 kW, supply voltage 380V. The purpose of the pumping station is to take raw materials from the supply tanks, dose the components in a given ratio and feed them under pressure to the mixer. Performance management by means of an electronic frequency regulator. 11 options for the ratio of components "A" to "B": from 1 to 1 to 1 to 2, with a step of 0.1 along the isocyanate line (it is possible to change the ratio with a step of 0.1 and along the polyol line). Installation is executed on a wheeled frame - mobile. The machine is implemented on the principle of open architecture - the most convenient inspection, diagnostics and maintenance of components and assemblies is provided. All necessary hoses and hoses are supplied with the pumping station, based on the installation of the pumping station and tanks within a radius of 5 m from the manipulator. This model can only be used as a stationary pumping station for pouring foam.

2.2. Low-pressure mechanical mixer ZG016B for pouring polyurethane foam composition. Dimensions 500x180x140mm, with a weight of 25 kg. Motor power 0.55 kW, supply voltage 380V. The mixer is suspended on a manipulator in stationary conditions. Time of continuous work is not limited. It is completed with a hydropneumatic tank (GPB), which provides washing of the mixer with an open cycle. The necessary pipelines are supplied, based on the installation of the GPB within a radius of 5 m to the mixer.

2.3. Control panel ZG016B. designed for the convenience of controlling the polyurethane foam production process from a single unit (PENA-20P75UM and ZG-016B are connected to this console), automation and control of the injection of the composition, control of the washing process. The unit is mounted in close proximity to ZG-016 in such a way that the operator can control the mixer levers and remote control buttons without leaving the place.

2.4. Manipulator (allows you to move the ZG-016 with a small effort of the hand in a circle and up and down). The manipulator is rigidly attached to the floor. Manipulator height 2200 mm, boom length 2500 mm. The horizontal angle of movement of the crane beam of the manipulator, between the boundary positions is 120 degrees. The mixer, mounted on the crane beam of the manipulator, can move vertically up to 0.8 m. The initial suspension height is adjustable.

2.5. Two 227L feed tanks for raw materials (provided with filter elements) and polyol mixing system. A recirculation system for both components is provided.

2.6. Compressor station K25M. Compressed air working pressure 4 kg/cm2, consumption from 500 liters per minute. Air is supplied to the GPB for washing and purging the mixer at the end of work. It is allowed to use other sources of compressed air that provide the specified parameters in terms of productivity and pressure.

Table 1

NOTE

It is allowed to exclude “Manipulator” from the list (on the spot you will mount a device that is most suitable for your purposes). It is economically more efficient and technologically more intelligent to make several injections (transitions from form to form) before the washing cycle begins. The filling machine allows 10 such injections, separated by no more than 12 seconds, and only then flushing the mixing chamber.

In the very first approximation, the molds can be laid out on the floor in a semicircle (or in a line) so that the Pouring Head, suspended from the manipulator beam, is able to move in a circle (or along) relative to the manipulator post. Then the operator, having filled in the first form, moves to the second one, at which time his assistant closes the completed form, and so on. The last point where the operator brings the mixer is the container for the release of the solvent during flushing.

3. Choice of sizes and number of molds

The main requirements for the formwork are the exact correspondence of the geometric dimensions of the form to the dimensions of the required part and high strength characteristics (polyurethane foam, when expanded, creates an excess pressure inside the form - 24 atm.). The mold is pre-lubricated with anti-adhesive grease.

Suppose there are 2 molds 1500 x 1000 x 50mm and two liners 1500 x 1000 x 10mm.

NOTE.

When gluing three plates, one plate with a quarter-joint should be obtained. To do this, you will need to use additional inserts. If you need to get a connection with a height of 75x75, then two inserts. If it is enough to get a connection with a height of 100x50, then one liner.

Table 2

Thus, 1 removal is carried out from the mold every 20 full minutes, i.e. 3 plates per hour.

The desired need is 225 cubic meters of slabs with a thickness of 150mm, which corresponds to 1500 m2 of slabs. Accordingly, with dimensions of 1500x1000 mm, this is 1000 GLUED slabs. To get them, you need to glue 3000 plates 1500x1000x50 mm.

With an eight-hour working day, 24 plates will be removed from one mold. From two forms - 48 pcs. Thus, it will take 3000 / 48 = 62.5 working days to obtain the desired volume.

If you limit the production time by half (1 month), then 4 forms will be required.

The need for slabs with a thickness of 130 mm is also 225 cubic meters, which corresponds to 1730 m2 of slabs. Accordingly, with dimensions of 1500x1000 mm, this is 1154 GLUED slabs. To get them, 3462 plates should be glued, of which 2308 plates will be 40 mm thick, and 1154 - 50 mm thick.

Similar to the calculation above, it is obvious that to obtain 3462 slabs, it will be necessary to provide filling in two molds within 72 days (with a possible productivity of 48 slabs per day).

If you limit the production time by half (36 days), then 4 forms will be required.

The tooling costs are given below (assuming that the "quarter" connector is provided with dimensions of 100x50).

To organize the production of polyurethane foam boards, a room is required, which should be divided into 5 sections: a warehouse for raw materials; section for cutting facing material; filling area; finished goods warehouse; compressor.

Raw material warehouse

The warehouse should be able to accept components (forklift or trestle) arriving, as a rule, in 200 liter drums. The raw materials warehouse should be located close to the pouring area. Possibly in the same room. Temperature for storage of components +15…+220С.

Section for cutting facing material

Heat-insulating boards can also be produced with an outer protective sheath, in particular, laminating with foil, fiberglass is common. In order to obtain such a coating, an appropriate facing material is placed on the bottom of the mold and smoothed out.

Pour area

Also, the room must be equipped with a supply and exhaust ventilation system that provides 10-fold air exchange per hour. air temperature at the pouring site +20…+220С.

At the pouring site, it is necessary to provide a place for temporary exposure of the manufactured plates (at least 3 hours at a temperature not lower than +200C) and means of monitoring the quality of products. In the same place, it will be necessary to glue three plates into one.

Finished goods warehouse

Finished slabs after curing and gluing are transferred to the finished product warehouse, where they are stacked. Packing is provided if necessary. The air temperature in the warehouse is not lower than +150С.

Compressor

A small room (preferably isolated), no more than 4 m2 or a spacious wooden box where the compressor is placed. This room should be ventilated from time to time.

5. Calculate the cost of raw materials, lubricant, solvent, glue and electricity.

We will calculate the required amount of raw materials, lubricants, solvents and glues in relation to the problem under consideration.

Raw material

The enterprise must supply 4154 slabs 1500x1000x50mm and 2308 slabs 1500x1000x40mm.
The mass of the plate 1500x1000x50mm with a density of 60 kg/m3 is:
60 x 1.5 x 1 x 0.05 = 4.5 kg. This is how much raw material should be used to get one product. Total total consumption of raw materials for 4154 plates 1500x1000x50mm: 18693 kg.
The mass of the plate 1500x1000x40mm with a density of 60 kg/m3 is:
60 x 1.5 x 1 x 0.04 = 3.6 kg. This is how much raw material should be used to get one product. Total total consumption of raw materials for 2308 plates 1500x1000x40mm: 8307 kg.
The total consumption of components "A" and "B" will be 27,000 kg. The cost of 1 kg varies from 110 to 130 rubles. Let's take the price of 1 kg at 125 rubles, respectively, the total cost of raw materials will be: 3375000 rubles.

Lubricant

Based on the release program, it is planned to carry out 6462 removals from 8 molds. Grease consumption per 1 product is 0.1 kg. Accordingly, 646.2 kg of lubricant will be required (for example, PENTA-120, costing 118 rubles / kg). That. lubrication costs will amount to 76,252 rubles.

Wash (solvent)

Based on the release program, it is planned to carry out 6462 removals from 8 molds. When optimizing the process, all 8 molds should be poured in 1 cycle, in this case there will be only one washing cycle after all the molds are filled.

That. there will be 6462 / 8 = 808 filling cycles, hence the same number of washes. Solvent consumption during one flush is 0.25 kg. Those. 202 kg of solvent will be required, at a price of 60 rubles / kg, i.e. 12 120 rub. Considering that 8 plates are produced in 1 cycle and 0.25 kg of solvent is consumed, therefore, the solvent consumption for 1 product is 0.0313 kg.

Glue

When gluing three plates into one product, you will need to use glue to connect the two surfaces. Glue consumption is from 150 to 400 grams per 1 m2 (depending on the quality of the surface - the presence of shells, cracks, etc.). We will take the normal consumption (based on the fact that high-quality forms and compliance with the technology make it possible to obtain high-quality products) of glue for 0.200 kg per 1 m2, i.e. 0.3 kg of glue is required for gluing two plates with an area of 1.5 m2. 1 kg of special polyurethane adhesive "KIMPANAT" costs 131 rubles.

To obtain 1000 GLUED slabs 1500x1000x150 mm, 3000 slabs 1500x1000x50 mm should be glued, i.e. spend 2000 x 0.3 \u003d 600 kg, which is equivalent to 78,600 rubles.

To obtain 1154 GLUED slabs 1500x1000x130 mm, it is necessary to glue 2308 1500x1000x40 mm and 1154 slabs 1500x1000x50 mm, i.e. spend 2308 x 0.3 \u003d 692 kg, which is equivalent to 90,704 rubles.

In total, the total consumption of glue will be 169,304 rubles.

Electricity

The consumption of electricity required to produce a given volume can be calculated based on the fact that there are 808 injection cycles in 8 molds.

Power consumption of the pumping station 2.2 kW/hour, filling head 0.55 kW/hour, compressor 5 kW/hour.

In a cycle with filling 8 molds, the pumping station works no more than 2 minutes, the filling head - 4 minutes, the compressor - no more than 1 minute. When performing 808 cycles, electricity consumption occurs: 808x (2.2x2 / 60 + 0.55x4 / 60 + 5x1 / 60) \u003d 808x (0.073 + 0.036 + 0.083) \u003d 808x0.192 \u003d 155 kW.

In total, the total electricity consumption (excluding lighting) for this scope of work is 155 kW. We will accept a possible correction based on a coefficient of 1.5 (they blew more air than it should be, the CG was idling, recirculation was carried out, etc.). As a result, we get the power consumption at the level of 232 kW.

Let's take the price of 1 kW / h for 7 rubles, then the cost of electricity consumed will be 1624 rubles. That. the consumption of electricity for the manufacture of 1 plate is 0.036 kW.

Wage

It should also provide for the wages of workers. 1 pouring machine operator and 2 (minimum) assistants are recommended.

Let's bring together the costs described above and determine the cost of one product and the total need for funds for the production of the desired volume of plates.

Total for 1 GLUED PLATE 1500x1000x150mm at a density of 60 kg/m3, costs (cost, excluding wages) will amount to 1808 rubles. 76 kop.

Total for 1 GLUED PLATE 1500x1000x150mm with a density of 60 kg / m3, the costs (cost, excluding wages) will amount to 1582 rubles. 62 kop.

The cost of purchasing equipment will be:

In total, for the independent production of a given volume of PU foam boards, you will need RUB 1,556,628 to purchase equipment and 3 635 109 rubles. for the purchase of raw materials, lubricants, washes, glue. Total, total capital investment RUB 5,191,737

Organization of production of heat-insulating semi-cylinders (shells) from polyurethane foam

1. General information

Heat-insulating semi-cylinders (shells) made of polyurethane foam (PPU) are used for thermal insulation of gas and oil pipelines, pipelines for hot and cold water supply, engineering networks of chemical and petrochemical industries, tanks, storage facilities, tanks and other industrial facilities, refrigeration and cryogenic equipment and temperature range from - 190С to +140С.

The flammability of PPU products is determined according to GOST 12.1.044-84, flammability class G2 (flammable, flame-retardant)). By using flame retardant additives in the production of polyurethane foam products, it is possible to increase the operating temperature range. The same effect can be achieved if the inside of the shell is made from a more heat-resistant material.

PPU is resistant to solvents, acids and alkalis, is not affected by fungus, does not collapse, is not affected by hot water, rodents.

Thermal insulation products made of polyurethane foam for pipeline insulation are made in the form of half-cylinders (for large diameters - segments of 120 or 90 degrees), tees, bends and other products according to technical requirements Customer.

The most common products obtained by pouring polyurethane foam are heat-insulating semi-cylinders used as thermal insulation for pipe sections during overground and channel laying of pipelines. If underground and channelless laying is assumed, then the pipeline with mounted shells must be treated with a continuous (without breaks) waterproofing and protective coating, for example, with TERMA tape.

The main advantages of polyurethane foam insulation are: low labor intensity of installation, the possibility of reusable use, quick access to damaged areas.

Heat-insulating shells can be made with an additional lining of fiberglass, fiberglass, foil and other materials.

Semi-cylinders are mounted on the pipeline using wire or tape clamps, ties, staples or adhesives.

In the case of using TERMA tape, there is no need for lining the shells, as well as the need for clamps - TERMA products reliably protect the shell from any external factors (moisture, sun, vandals). To learn more about the TERMA tape and the use of PPU-scorlum for installation, click here.

2. Equipment model selection

The choice of equipment model is directly related to the inner diameter and thickness of the shell, which is supposed to be produced (more precisely, the mass of the shell). This is due to the technological process of manufacturing polyurethane foam products by pouring.

The two liquid components are mixed and fed into the mould.
The composition “starts” very quickly, i.e. there is an increase in volume (tens of times). As a rule, the "start time" is 18-25 seconds. The time during which the liquid is injected into the formwork is called the "injection time".

It is forbidden to continue injection of components into the mold if the increase in foam volume has begun. In this case, you may not have time to close the form, and the product will be damaged.

The maximum allowable injection time should not exceed 80% of the start time, as it takes more time to close the form and fix its locks. But this procedure should be given at least 5 seconds.

For example, if the start time of the composition is 25 seconds, then the allowable injection time is 0.8x25=20 seconds.

That. the maximum possible mass of the final product is limited by the mass of the components mixed in the mixer, which the pumping station pumps at maximum capacity in 20 seconds.

NPF "NST" completes filling machines with two types of pumping stations:

FOAM-20P20UM4, with a capacity of 1 to 6 liters per minute (with the ratio of components "A" to "B" - 1 to 1);
FOAM-20P75UM, with a capacity of 8 to 24 liters per minute (at a ratio of components "A" to "B" - 1 to 1).

The density of the polyol, as a rule, is 1.04, the density of the isocyanate is 1.24 kg/m3. Then, with the weight ratio of components "A" and "B" corresponding to 1 to 1, the density of the mixture "A" + "B" (in the liquid state, before the start) is 1.14 kg/m3.

That. the maximum possible mass of the product obtained at various pumping stations is:

2.28 kg for FOAM-20P20UM4 with a capacity of 6 liters per minute (with the ratio of components "A" and "B" as 1 to 1), injection time 20 seconds;
9.12 kg for PENA-20P75UM with a capacity of 24 liters per minute (with the ratio of components "A" and "B" as 1 to 1), injection time 20 seconds.

The normal density of the foam directly in the product is from 40 to 50 kg/m3. At the same time, the shells have good mechanical strength, low coefficient of thermal conductivity. An increase in the density of the product does not improve the quality of products, but only leads to an increase in the cost of half-cylinders.

If we take the maximum density of the foam in the product as 50 kg / m3, then we can calculate the maximum volume finished products, based on the maximum possible injection mass for each of the pumping stations:

FOAM-20P20UM4 - 2.28 kg / 50 kg / m3 = 0.045 m3 for 1 injection lasting 20 seconds;
FOAM-20P75UM - 9.12 kg / 50 kg / m3 = 0.182 m3 for 1 injection lasting 20 seconds.

Table 1 shows the parameters of various semi-cylinders 1 m long at a density of 50 kg/m3. Those. the “bad” option was considered, at maximum density (in practice, shell manufacturers try to maintain density in the range of 40-45).

Table 1

Shell thickness, mm	Volume of 1 half-cylinder, m3	Density, kg/m3	Weight, kg

Thus, the pouring machine based on the PENA-20P20UM4 pumping station can be used without restrictions for casting shells with an internal diameter of up to 426 mm inclusive, if the injection is carried out in a “semi-cylinder” mold, the start time of the composition is 25 seconds, and the density of the final foam is not higher 50 g/m3.

NOTE:
Theoretically, the 530th shell also "passes"; 2.2765 kg LESS than 2.28 kg. But the difference is only 3.5 grams, which is negligible in relation to the productivity of the installation per second (114 gr. / s), respectively, it is impossible to guarantee 100% that the Du530 shell with a thickness of 50 mm will be obtained under the given injection conditions. The problem can be solved if the injection time is increased by 1-2 seconds or the start time is increased by 1-2 seconds or the shell density is reduced, for example, to 45kg/m3.

If you use a filling machine based on the PENA-20P75UM pumping station, then there are no restrictions on the diameter and thickness of the shell, because the mass of the half-cylinder at DN1020 is 4.1998 kg, which is much LESS than 9.12.

NOTE:
The pumping station FOAM-20P20UM4 can also be used for PPU SPRAYING. Therefore, if you do not intend to produce shells above DN530, then this option is more correct. If necessary, it is possible to replace the Filling Head with a sprayer and carry out thermal insulation work on the construction site (including spraying PPU on pipelines).

NOTE:
If necessary, it is permissible to increase the start time up to 30 seconds. Then the injection time is 24 seconds, respectively, the injection mass will also increase.

3.1. Model P20UM4-ZG016M. Shell production (DN426 mm)

3.1.1. Pumping station PENA-20P20UM4, capacity from 1 to 6 l/min, has dimensions 1150x550x900mm and weight 85kg. Motor power 0.75 kW, supply voltage 220V. The purpose of the pumping station is to take raw materials from the supply tanks, dose the components in a given ratio and feed them under pressure to the mixer. Performance management by means of an electronic frequency regulator. 11 options for the ratio of components "A" to "B": from 1 to 1 to 1 to 2, with a step of 0.1 along the isocyanate line. This model can also be used as a pumping station for foam spraying. In this case, it should be completed with a sprayer. The unit is made on a wheeled frame - mobile (easily transported, including over rough terrain). The machine is implemented on the principle of open architecture - the most convenient inspection, diagnostics and maintenance of components and assemblies is provided. The pumping station is supplied with all the necessary hoses and hoses, based on the installation of the pumping station and tanks within a radius of 5m from the manipulator.

3.1.2. Low-pressure mechanical mixer ZG-016M for pouring polyurethane foam composition. Dimensions 500x180x140mm, with a weight of 24kg. Motor power 0.55 kW, supply voltage 380V. The mixer is suspended on a manipulator in stationary conditions. Time of continuous work is not limited. It is completed with a hydropneumatic tank (GPB), which provides washing of the mixer with an open cycle. The necessary pipelines are supplied, based on the installation of the GPB within a radius of 5 m to the mixer.

3.1.3. The ZG-016M control panel is designed for the convenience of controlling the polyurethane foam production process from a single unit (PENA-20P20UM4 and ZG-016M are connected to this panel), automating and controlling the injection of the composition, and controlling the washing process. The unit is mounted in close proximity to ZG-016 in such a way that the operator can control the mixer levers and remote control buttons without leaving the place.

3.1.4. Manipulator (allows you to move the ZG-016 with a small effort of the hand in a circle and up and down). The manipulator is rigidly attached to the floor. Manipulator height 2200mm, boom length 2500mm. The horizontal angle of movement of the crane beam of the manipulator, between the boundary positions is 120 degrees. The mixer, mounted on the crane beam of the manipulator, can move vertically up to 0.8 m. The initial suspension height is adjustable.

3.1.5. Two consumable containers of 227l (or 67l - at the choice of the Customer) for raw materials (equipped with filter elements) and a polyol mixing system. A recirculation system for both components is provided.

3.1.6. Compressor station K25-M. Compressed air working pressure 4kg/cm2, consumption from 240 liters per minute. Air is supplied to the GPB for washing and purging the mixer at the end of work. It is allowed to use other sources of compressed air that provide the specified parameters in terms of productivity and pressure.

table 2

3.2. Model P75UM-ZG016B.

3.2.1. Pumping station FOAM-20P75UM, capacity from 8 to 24l/min, has dimensions 1250x650x1000mm and weight 180kg. Motor power 2.2 kW, supply voltage 380V. The purpose of the pumping station, performance management, changing the ratio of components, the design of the installation, the scope of delivery are similar to the PENA-20P20UM4 model. There is a difference - the impossibility of using this pumping station for spraying polyurethane foam (due to high productivity). This model can only be used as a stationary pumping station for pouring foam.

3.2.2. Low-pressure mechanical mixer ZG-016B for pouring polyurethane foam composition. Dimensions 550x180x140mm, with a weight of 25kg. Purpose, design and other parameters coincide with the ZG-016M model.

3.2.3. Control panel ZG-016B. Unlike the ZG-016M remote control, it is equipped with electronic system adjustment of the injection time with an accuracy of 0.1 s. The performance of the pumping station is also controlled from the remote control. Designed to connect a pumping station with a power of 2.2 kW at a supply voltage of 380V.

3.2.4. The manipulator is absolutely identical to the P20UM4-ZG016M model.

3.2.5. Two consumable containers of 227 liters each are absolutely identical to the P20UM4-ZG016M model.

3.2.6. Compressor station K25-M. The purpose and parameters of compressed air are absolutely identical to the P20UM4-ZG016M model.

Table 3

*The cost of equipment is given as of the winter of 2018 and may differ from the actual cost on this moment. The current prices are given in the "Price List" section.

4. Choice of sizes and number of molds

Forms are a necessary element of production. The volume of finished products, the timing of the order are directly related to the number of forms and their standard sizes. The need for molds comes from the technological process, the essence of which is that in order to obtain a polyurethane foam half-cylinder, a mixed composition of components "A" and "B" is poured into a restrictive tooling (Fig. 1).

The main requirements for the formwork are the exact correspondence of the geometric dimensions of the form to the dimensions of the required part and high strength characteristics - polyurethane foam, when expanded, creates an excess pressure inside the form of 2-4 atmospheres.

The mold is pre-lubricated with anti-adhesive grease. The number of standard sizes of forms directly depends on the demand for a specific diameter of the foam shell. The diameters that are most in demand should be identified so as not to invest in molds that will not be needed or will be rarely used.

The number of molds of each standard size should be calculated based on the time within which a specific batch of products should be manufactured.

There are two types of molds: semi-cylinder and cylinder. From the molds of the first type, respectively, one half of the shell is cast, and from the molds of the second type, respectively, two halves.

Due to the design features of these two types of forms, the time spent on the execution of the process steps associated with their use are different. As an example, the table below shows expert estimates of the time spent for two types of molds with an internal diameter of the shell greater than 133 mm, but less than 219 mm.

Table 4

Name	Half-cylinder shape	Shape "cylinder"
Form lubrication
Form Assembly	Not required
Injection of the composition into the mold
Form excerpt
Form opening
Dismantling the mold for product excavation	Not required
Product removal
Form cleaning
Partial mold assembly	Not required

Thus, from the “half-cylinder” mold, 1 removal is carried out every 15 minutes, i.e. 2 p.m. shells per hour. The “cylinder” shape, at first glance, is more productive: it allows you to get 2 running meters. shells in 54 minutes. Those. on average, for one work shift, additionally receive 2 running meters. shells.

But it should be borne in mind that it is more difficult to maintain the “cylinder” shape; additional devices will be needed for its disassembly and assembly. It will not work to remove the product directly at the pouring site, you will need to transfer the mold from the pouring site, then transport it back accordingly. All this can increase the processing time of the “cylinder” shape so much that the benefits of an additional 2r.m. may or may not be replaced.

In addition, it should be taken into account that it is difficult for one person to process the “cylinder” shape (especially starting from the 159th diameter), two people do it, while all operations with the “half-cylinder” shape can be performed by one person (assistant pouring machine operator). Therefore, a more rational choice is to use half-cylinder shapes.

Exposure in the form of a shell with an internal diameter below 159 mm can be reduced to 10 minutes, then the full cycle of use of the form will be reduced to 12 minutes, respectively, one form will allow you to get 5 pm. for 2 hours. Exposure in the form of a shell with an internal diameter above 426 mm is recommended to be increased to 18 minutes, then the full cycle of using the form will increase to 20 minutes, respectively, one form will allow you to get 3 running meters. for 2 hours.

Thus, one form from the 57th to the 133rd diameter with an 8-hour working day allows you to get 20 running meters. shells. One form from the 159th to the 426th diameter with an 8-hour working day allows you to get 16 running meters. shells. One form from the 530th to the 1020th diameter with an 8-hour working day allows you to get 12 running meters. shells.

Based on certain standards, the volume and timing of the average order, it is necessary to determine the number of required forms of each standard size. This task is all the easier if the main consumer of the product is known in advance. For example, equipment is purchased for a specific order or a long-term agreement has been signed with housing and communal services, a water utility or another organization that can inform in advance the diameters of pipes to be insulated.

Otherwise, market research should be carried out and the need for shells of each diameter should be assessed on a 10-point scale, in relation to a particular sales region.

1) If the need for a shell of one or another diameter is less than 5 points, then it is not advisable to initially purchase formwork for its production. The probability of ordering is small and it is more correct to purchase the form or forms directly if there is demand.

In this case, the client can be explained that the products he is interested in are in little demand and are rarely asked, so it is desirable to receive an advance, for example, 50% of the order value. Otherwise, if the customer changes his mind (purchases the shells in another place, uses other methods of isolation), you can be left with little liquid goods in the warehouse, for the production of which funds were spent.

This approach should not be applied to long-term partners, regular customers.

You should be careful before explaining to the customer that molds will be made (purchased) especially for him. If there is a competitor in the region who has formwork of the required diameter, he will be able to offer shorter lead times. Then you can keep a potential customer only at a lower price.

It should be borne in mind that the production time for NPF NST forms is from 5 to 10 days, then delivery time is required.

2) If the need for a shell of a particular diameter is estimated from 5 to 7 points, then it is recommended to initially purchase 1 form of this size. This will be enough to start fulfilling the order, and if necessary, to buy additional equipment.

3) If the need for a shell of one or another diameter is estimated from 8 to 10 points, then the number of purchased forms directly depends on the volume of the average order and the acceptable deadlines for its execution.

In table. 5 shows the choice of sizes and the number of forms, carried out by one of the firms in the Moscow region, based on the marketing research market.

Table 5

Shell inner diameter, mm	The rate of "removal" of the shell per shift from one form	The need for shells on a 10-point scale	Average order quantity for shells of a given diameter	Maximum delivery time, days	The number of molds that need to be purchased at the same time as the equipment








					Of necessity

					Of necessity
					Of necessity
					Of necessity
					Of necessity
					Of necessity
					Of necessity

Further calculations will be based on the nomenclature selected in the table. 5 forms. Let's also assume that the company has signed a Contract for the supply of shells of the above standard sizes in the amount of 300, 320 and 200 running meters. and she is faced with the task of choosing a plant model, purchasing equipment, molds, mounting it and delivering products to the customer.

5. Estimating the cost of purchasing equipment, tooling and accessories

The current need of the company is the production of shells of the 57th, 159th and 219th diameters. The production of shells from 426 to 1020 diameter is estimated as unlikely.

It should be borne in mind that pipelines with a diameter above 426 are conveniently insulated by spraying. If there is an order for shells of large diameters, we can offer to execute it by spraying with polyurethane foam (you will need to purchase raw materials for spraying). It will be faster and easier than buying new equipment, which you may not have to use later. For spraying polyurethane foam, the FOAM-20P20UM4 installation, equipped with a sprayer, is used. To work, you need a K-25M compressor.

Based on point 2 and an assessment of the demand for various standard sizes of shells (Table 5), a choice is made in favor of a filling machine based on the PENA-20P20UM4 pumping station. This model, under any conditions and any raw material, will make it possible to obtain shells up to the 426th diameter, and with certain raw materials (the start time is at least 25 seconds and the density of free foaming is not more than 45 kg/m3), to obtain shells up to the 530th diameter.

The cost of equipment (without a compressor) in accordance with paragraph 3 is 377,487.01 rubles. The cost of molds is estimated based on the required range of formwork (Table 6) and the cost of equipment.

Table 6

Pipe diameter, mm	Shell thickness, mm	Shell segment angle, deg.	Segment size tolerance, mm	price, rub.
				negotiable

NOTE: molds for diameters 720, 820 and 1020 are made with a segment angle of 120 degrees, i.e. one cylinder is joined on a three-piece pipe.

Table 7

Pipe diameter, mm	Quantity, pcs.	Price for 1 piece, rub.	Cost, rub.
		negotiable	negotiable

The next expense item is additional accessories to facilitate the process of bringing the Pouring Head to the molds. It is economically more efficient and technologically more intelligent to make several injections (transitions from form to form) before the washing cycle begins. The filling machine allows 10 such injections, separated by no more than 12 seconds, and only then flushing the mixing chamber.

The first, easiest way is to lay out the forms on the tables in a semicircle, because. The pouring head, suspended from the manipulator beam, is able to move in a circle relative to the manipulator stand. Then the operator, having filled in the first form, moves to the second one, at which time his assistant closes the completed form, and so on. The last point where the operator brings the mixer is the container for the release of the solvent during flushing.

Another method involves the installation of a carousel-type conveyor at the casting site, which provides supply and fixation in the mold casting area. Several forms are compactly placed on this device.

The carousel rotates around its axis, moving the forms installed on it around the circle. There is no need to move the head. She is motionless. After injection into the first mold, the operator's assistant rotates the conveyor so that the second mold is under the Pouring Head. In this case, the first one is opposite him - he closes the form and fixes its locks. At this time, the operator injects into the second mold. The cycle is repeated until all the forms mounted on the carousel pass under the head. The operator can then move the head around the circumference to the second carousel, where all forms will also be filled. Then the head is taken to the washing zone, fixed over the container and washed. The technological chain of moving the Pouring Head between the two carousels and the rinsing tank is shown in fig. 3.

The dimensions (diameter) and weight of the carousel depend on the number of forms to be installed. For example, for a four-form carousel, these are 1200 mm and 120 kg; for a carousel for six molds, it is 1600 mm and 160 kg.

Such a conveyor provides the possibility of placement and operation even in an unprepared production room.

It is technologically more convenient to pour molds of the same standard size in a row (because with each change in standard size, the injection time on the control panel should be adjusted). Therefore, for the considered variant of the organization of the production site, where it is supposed to use the standard sizes of the forms, in the amount specified in Table. 7, it makes sense to purchase and mount 2 carousels, respectively, for 6 and 4 slots. The cost of the first is 58,262 rubles, the second is 45,578 rubles. In total, the cost of such equipment will amount to 103,840 rubles.

Another of the additional devices can be a heating cabinet, where the molds are heated to a temperature of + 27 ... + 30 degrees C. But on initial stage this option can be waived if the molds are stored in the pouring area, where a constant temperature of +20 ... + 22 degrees C is maintained. Moreover, if the shell production process is constant, i.e. the form after the shell is removed (the formwork is still warm) is immediately poured again, then there is no need for forced heating.

6. Requirements for the production room

To organize the production of PU foam shells, a room is required, which should be divided into 5 sections: a warehouse for raw materials; section for cutting facing material; filling area; finished goods warehouse; compressor.

Warehouse of raw materials.

The warehouse should be able to accept components (forklift or trestle) arriving, as a rule, in 200 liter drums. For operation, polyol and PIC must be poured from tare tanks into feed tanks. Transfer can be carried out incl. and by means of the pumping station of the filling machine. To do this, the suction pipes (if necessary, lengthen) are removed from the supply tanks and immersed in container barrels, then the start-up is carried out in the recirculation mode and the raw material is poured into the working tanks. It is possible to use NMSh 8-25-6.3/109AIR00L4 pumps for pumping components from container drums into working containers.
The raw materials warehouse should be located close to the pouring area. Possibly in the same room. Temperature for storage of components +15…+22grad.С.

Section for cutting facing material.

Heat-insulating shells can also be produced with an outer protective shell on customer's request, in particular, laminating with foil, fiberglass, fiberglass or galvanized casing is common.

To obtain such a coating, an appropriate facing material is laid and smoothed on the bottom of the mold.

An area should be provided, preferably in the immediate vicinity of the casting site, where the facing material will be delivered (as a rule, it comes in rolls) and laid out (unwound) on the cutting table. For each heat-insulating element, a piece of facing material is cut out according to the pattern in the form of a rectangle, the length of which corresponds to the length of the heat-insulating element (1 m), and the width corresponds to the outer segment of the shell surface.

The number of blanks is determined based on the planned amount of work per shift, and is prepared in advance. The prepared material is stored in a straightened state, excluding its damage (gusts and wrinkling). The cutting area is located close to the pouring area. Possibly in the same room.

Pour area.

At this site, a filling machine, carousels, a container for discharging flushing liquid are mounted.

As this container, you can use a metal 200 liter barrel, in the lid of which there should be two holes: a diameter of 60-80mm (standard exit from the barrel) and a diameter of 150-200mm (should be cut additionally).

In this second, large hole, flexible or rigid piping should be installed that extends outside the room (to the street). At the end of this pipeline, an exhaust device must be mounted, which, in this way, will suck methylene chloride vapor from the barrel and remove them from the building. For the purposes of ecology, a system of filters that trap harmful substances should be installed at the outlet of the specified pipeline.

At the beginning of the work shift, the exhaust from the waste tank turns on, and turns off when all work is completed, at the end of the day.

The barrel should be positioned in such a way that when the manipulator arm is rotated, the pouring head is fixed vertically directly above the small hole. Moreover, the nozzle of the filling head should be located at a height of 20-30 mm from the plane of the hole, so that when washing, the entire solvent flow enters the drain tank.

Also, the room must be equipped with a supply and exhaust ventilation system that provides 10-fold air exchange per hour. The air temperature at the pouring area is +20…+22 degrees C.

The site should provide a place for storing all unused molds. Perhaps along the walls, in the immediate vicinity of the radiators. In the same place, at the pouring site, it is necessary to provide a place for temporary exposure of the manufactured shells (at least 4 hours at a temperature not lower than + 20 degrees C) and a means of controlling the quality of products.

Finished goods warehouse.

Finished semi-cylinders after exposure are transferred to the warehouse of finished products, where they are stacked. Packing is provided if necessary. The air temperature in the warehouse is not lower than + 15 degrees C.

Compressor.

An approximate plan of the production shop is shown in Fig. 4.

The area of each specific site is determined based on the production capacity and the maximum load on each technological site. In relation to the problem under consideration (Table 6), the enterprise must supply 300 m.p. within 4 days. shells Du57, 320 m.p. shells Du159 and within 5 days 200 m.p. shells Du219. Assume that this entire order is received and accepted for production at the same time.

Thus, the maximum number of shells that will accumulate at the beginning of the 5th day in the warehouse of finished products (on the day of shipment DN57 and DN159) is: 300 m.p. Du57, 320 m.p. DN159 and 192m.p. Du219.

Let's take the height of the ceilings of the room 3m. The outer diameter of the shell Du57mm is 137mm, the outer radius is 69mm. Then 7 half-cylinders can be laid on 1m2 of area. Based on the convenience of warehousing, the maximum stacking height is assumed to be 1.5 m, then a total of 21 rows can be laid per 1 m2. Total 21x7 \u003d 147 half-cylinders or otherwise 73 running meters. shells Du57mm. Considering that the total volume of the shell of a given diameter to be stored is 300 m.p., then 5 m2 will be required in the warehouse.

The outer diameter of the shell Du159mm is 239mm, the outer radius is 120mm. Then 4 half-cylinders can be laid on 1m2 of area. Based on the convenience of warehousing, the maximum stacking height is assumed to be 1.5 m, then a total of 13 rows can be laid per 1 m2. Total 13x4 \u003d 42 half-cylinders or otherwise 21 running meters. shells DN159mm. Given that the total volume of the shell of a given diameter to be stored is 320 m.p. it is obvious that in the warehouse this will require 16 m2.

The outer diameter of the shell Du219mm is 299mm, the outer radius is 150mm. Then 3 half-cylinders can be laid on 1m2 of area. Based on the convenience of warehousing, the maximum stacking height is assumed to be 1.5 m, then a total of 10 rows can be laid per 1 m2. Total 10x3 \u003d 30 half-cylinders or otherwise 15 p.m. shells Du219mm. Considering that the total volume of the shell of a given diameter to be stored is 192 m.p. it is obvious that in the warehouse this will require 13 m2.

It is necessary to provide a 2-fold margin for the area of the warehouse, i.e. 64 m2 of area, in addition, it is necessary to provide passages between the stacks and a platform in front of the door. The plan for organizing a warehouse for finished products is shown in fig. 5. Warehouse area 10x11=110m2.

The photo below shows the finished product warehouse of SovTekh LLC, one of the largest and most advanced shell manufacturers in the Siberian region.

The section for cutting facing material involves the installation of a table 3x1.5 m, a device for unwinding rolls, and installation of stands for cut and prepared facing elements. It should also provide for the possibility of free movement on the site and the possibility of approaching the table, stands from any side.

The optimal area of the site is 4x6 \u003d 24 m2.

In the warehouse of raw materials, it is enough to have space for a one-time placement of 3 tons of raw materials, 200 kg of solvent, 3 rolls of facing materials. It should also provide for the possibility of free movement between barrels. The plan for organizing a warehouse for raw materials is shown in fig. 7. Warehouse area 7x8=56m2.

The area for the primary holding of products (at a temperature not lower than +20 degrees C) means the storage of finished products during the first 3 hours from the moment of demoulding. Taking into account that the maximum number of “removals” from one form per hour is 4 products, i.e. 12 semi-cylinders in 3 hours, and in total 10 molds can be used on two carousels or no more than 20 molds with constant rotation, then this section should contain up to 120 m.p. shells. It is enough to provide 6m2 where the preliminary exposure will be carried out, or to ensure the convenience of passage on the site, an area of 3x7 = 21m2 is recommended. The site organization plan is shown in fig. 8.

For the casting area (direct installation of equipment, carousels), to ensure ease of operation and maintenance, 7x7 = 42m2 is sufficient. The compressor can also be located there.

Thus, the total area of the production workshop should be at least 110 + 24 + 56 + 21 + 42 = 253m2.

7. Cost calculation for raw materials, lubricants and solvents

Let us calculate the required amount of raw materials, lubricants and solvents in relation to the problem under consideration (Table 5). The enterprise must deliver 300 m.p. shells Du57, 320 m.p. shells Du159 and 200 m.p. shells Du219.
Let us assume that the available raw materials and the conditions of the technological process make it possible to obtain a foam plastic in the form of a density of 45 kg/m3, then (see Table 1) it follows that the mass is 1 m.p. shell Du57 is 0.549 kg; shell Du159 is 1.125kg; shell Du219 is 1.464 kg.

The mass of the shell corresponds to the mass of raw materials spent on its production. · To obtain 300 m.p. DN57 shells require 300x0.549 = 165kg of components:

to get 320m.p. shells Du159 need 320x1.125=360kg of components;
to get 200m.p. shell Du219 requires 200x1.464 = 293kg of components.

The total mass of raw materials is 818 kg.

Before pouring the composition, each mold should be lubricated. Grease consumption for the Du57 mold is 10g, for Du159 it is 20g, and for Du219 it is 25g.

For the production of 300 m.p. shells should use the form 600 times, 320 m.p. - 640 times, 200 m.p. - 400 times. Accordingly, the required lubricant consumption: 0.01x600 + 0.02x640 + 0.025x400 \u003d 6 + 12.8 + 10 \u003d 28.8 kg.

At the end of the prime cycle, the head should be flushed with solvent. Liquid consumption 0.2 kg per cycle. To minimize the cost of this article, one flush after several injections should be carried out. To do this, it is necessary to optimize the technological sequence of the execution of this order.

There are two carousels for 4 and 6 slots, respectively. There are 4 forms DN57, which should be used every 150 times. There are 6 forms DN159 to be used every 107 times. There are 3 forms of DN219, which should be used every 134 times.

It is recommended to install molds DN159 on a carousel with 6 slots, three molds DN219 and 1 mold DN57 are installed on a carousel with 4 slots. 107 cycles of pouring into molds located on two carousels are carried out, while 107x0.2 = 21.4 kg of solvent is consumed. As a result, 640 semi-cylinders of the Du159 shell are obtained (i.e. 320 m.p.); 107 semi-cylinders of the shell Du57 (i.e. 53 m.p.); 321 semi-cylinder shell Du219 (i.e. 160 m.p.).

After that, it remains to receive: 493 semi-cylinders of the Du57mm shell and 79 half-cylinders of the Du219mm shell. 4 molds Du57mm are mounted on the first carousel, and 3 molds Du219mm are mounted on the second, then 26 pouring cycles are carried out, during which 26x0.2 = 5.2 kg of solvent is consumed. As a result, 79 semi-cylinders of Du219 shell (ie 40 rp) and 104 semi-cylinders of Du57 shell (ie 52 rp) were produced. As a result, it remains to finish 195 m.p. shells Du57. Available in 4 shapes Du57, they are installed on a small carousel. 98 pouring cycles are carried out, during which 98x0.2 = 19.6 kg of solvent is consumed.

Thus, the total consumption of the washing liquid is 21.4 + 5.2 + 19.6 = 46.2 kg.

8. Calculation of other costs

You should also take into account the wages of workers. Recommended 1 casting machine operator and 2 assistants. Let's suppose the operator's salary is 26,000 rubles, and the assistants are 20,000 rubles each, the total salary fund for service personnel is 66,000 rubles. If we assume that there are 4 working weeks in a month, and this order is fulfilled within 4-5 days, then the costs under this item in relation to the cost of manufactured products can be taken as 16,500 rubles.

The energy consumption required to produce a given volume can be calculated based on the fact that there are 107 injection cycles in 10 molds, 26 injection cycles in 7 molds and 98 injection cycles in 4 molds.
Power consumption of the pumping station 0.75 kW/hour, filling head 0.55 kW/hour, compressor 5 kW/hour.

With a cycle of filling 10 forms, the pumping station operates no more than 2 minutes, the filling head - 4 minutes, the compressor - no more than 0.25 minutes. During the implementation of 107 cycles, electricity consumption occurs: 107x (0.75x2 / 60 + 0.55x4 / 60 + 5x0.25 / 60) \u003d 107x (0.025 + 0.036 + 0.02) \u003d 8.75 kW.

With a cycle of filling 7 forms, the pumping station works no more than 1.5 minutes, the filling head - 3 minutes, the compressor - no more than 0.15 minutes. When performing 26 cycles, electricity consumption occurs: 26x (0.75x1.5 / 60 + 0.55x3 / 60 + 5x0.15 / 60) \u003d 26x (0.018 + 0.027 + 0.012) \u003d 1.5 kW.

With a cycle of filling 4 forms, the pumping station works no more than 0.8 minutes, the filling head - 1.6 minutes, the compressor - no more than 0.1 minutes. When 98 cycles are carried out, electricity consumption occurs: 98x (0.75x0.8 / 60 + 0.55x1.6 / 60 + 5x0.1 / 60) \u003d 98x (0.01 + 0.014 + 0.008) \u003d 3.14 kW.

In total, the total electricity consumption (excluding lighting) for this scope of work is 13.39. We will accept a possible correction based on a coefficient of 1.5 (they blew more air than it should be, the CG was idling, recirculation was carried out, etc.). As a result, we get the power consumption at the level of 20 kW.

Organization of the production of sandwich panels with polyurethane foam - PPU

1. Equipment model selection

The choice of equipment model is directly related to the dimensions of the product.

The essence of the technological process is that two liquid components (isocyanate and polyol) are mixed and fed into a certain form. After some time, the composition "starts", i.e. there is a noticeable increase in volume (tens of times), a change in color (whitening). As a rule, the "start time" is 18-25 seconds. The time during which the liquid is injected into the formwork is called the "injection time".

A prerequisite for obtaining a normal product is to stop the injection of the composition "A" and "B" before the start. The maximum allowable injection time must not exceed 80% of the start time. It is forbidden to continue injection into the mold if there is already an increase in the volume of foam mass. In this case, there is a real danger that it will not be possible to close the mold, and the product will be damaged (both the internal structure and the geometric contours).

For example, if the start time of the composition is 25 seconds, then the allowable injection time is 0.8x25=20 seconds.
That. the maximum possible mass of the final product is limited by the mass of the components mixed in the mixer, which the pumping station pumps at maximum capacity in 20 seconds.

NPF "NST" completes filling machines with two types of pumping stations:

FOAM-20P20UM4, with a capacity of 1 to 6 liters per minute (with the ratio of components "A" and "B" as 1 to 1);
FOAM-20P75UM, with a capacity of 8 to 24 liters per minute (with a ratio of components "A" and "B" as 1 to 1).

2.28 kg for PENA-20P20UM4 with a capacity of 6 liters per minute (with the ratio of components "A" and "B" as 1 to 1);
9.12 kg for PENA-20P75UM with a capacity of 24 liters per minute (with the ratio of components "A" and "B" as 1 to 1). The injection dose for 1 second is 0.456 kg.

The normal density of the foam directly in the product is from 40 to 60 kg/m3. At the same time, the thermal conductivity of the foam plastic practically does not depend on the density. A density of 40 suggests sufficient mechanical strength. Most manufacturers strive to minimize the density in the product, so this allows you to minimize the cost. Products with a density of 60 are made only if required by the customer. Or the density in the product increases when the technology is violated.

For further calculations, we assume that the final density of PU foam in the slab is 45 kg/m3.

Let us evaluate the stages of the technological process from a technical and economic point of view, based on the fact that it is necessary to produce a panel with a length of 6000mm, a width of 1200mm and a thickness of 100mm. Panel cladding on both sides - metal sheet 1mm. Let's assume that the need for panels is 2150 sq.m. per month.

The volume of polyurethane foam in the panel is 6 x 1.2 x 0.1 = 0.72 m3.

With a product density of 45 kg / m3, the mass of PPU will be: 0.72 x 45 = 32.4 kg. Therefore, the equipment model PENA-20P75UMZG-016B should be used, but filling must be carried out in several injections.

2. Technological sequence of pouring polyurethane foam

The maximum injection of the filling machine is 9.12kg, while 32.4kg is required. Standard solution in this case, it is the dissection of the panel into several isolated volumes. In this case, at least three sections are required.

The dissection is carried out using PPU-bars (it will be impossible to determine the presence of an insert after pouring PPU), the same material that is poured, the length of which corresponds to the width of the panel, and the height - to the thickness of the panel. For this case, it is proposed to use bars 1200x100x200 (increased width - for reliable (on a large plane) fixation of the bar to the shell sheet). To get three sections, you need to use two bars.

In this case, the volume of the panel filling will decrease by the volume of PPU liners, i.e. by 2x1.2x0.1x0.2=0.048 m3. Accordingly, the actual volume of pouring will be: 0.720.048=0.672m3, which at a density of PPU 45kg/m3 will be 0.672x45=30.24kg, i.e. the mass of PPU in one compartment is 10.08 kg.

Based on the maximum injection mass (at 20 seconds) of 9.12 kg, we have the need for an additional injection with a mass of 0.96 kg. Solve this question can be done in two ways:

1. Increase injection time. An additional 2.1 seconds is required, i.e. injection within 22.1 seconds, which, in principle, is acceptable.

NOTE
It is possible to increase the start time to 30 seconds, in which case the estimated maximum injection time will be 24 seconds.

2. Increase the width of the liner so that the additional volume of the liner compensates for 0.96 kg of foam, which is equivalent to 0.0213 m3. 1.2x0.1xS=0.0213, i.e. S=0.17m, i.e. 17cm. In other words, it is necessary to use two inserts with dimensions of 1.2x0.1x (0.2 + 0.17).

For this example, we will choose the second option.

At the first stage, both sheets of the casing are covered with a special primer designed to provide increased adhesion of the foam to the casing. Some enterprises (for example, the Lipetsk Metallurgical Plant) supply for the production of sandwich panels metal already treated with a composition that provides increased adhesion.

As an option, one-component (with solvent) primer ADV23, price 117 rubles / kg, consumption 150 300 gr. per sq.m.

Then the upper plane of the PPU-bars is smeared with glue. After that, this sheet and the second one (already treated with soil) are installed in the formwork (between two sheets of chipboard 30 mm thick). In this case, PPU bars are also glued to the second surface. The formwork ensures that the shell sheets are placed opposite each other.

It is also necessary to "close" the ends of the panel. When foaming, PPU will create pressure in the structure. To prevent the formwork from “squeezing out”, which deforms the panel, it is necessary to ensure a rigid fixation of the structure.

Then the filling process begins.

First, the operator on the control panel sets the injection time. In our case it is 20 seconds. However, it should be taken into account that after turning off the filling head and closing the taps, a small amount of raw material remains in the cavity of the chamber, which is also advisable to submit the form. In this connection, a slightly shorter time is set on the remote control, namely 19 seconds.

Then the pouring head is installed above the formwork, at point 1, and the injection starts. The task of the operator is to smoothly and evenly move the head towards point 2 within 19 seconds. After 19 seconds, the control panel will automatically turn off the supply of raw materials, and the operator should turn the handle of the “cut-off valves”, wait 23 seconds until the remnants of the mixed composition flow out of the CG chamber. Then the Head is transferred to point 3. At this time, starting from point 1 in the cavity, the start is already beginning.

In order to prevent the composition from escaping to the outside and to provide a slight over-sealing, it is necessary to apply from above the first section and fix the plate, the inside of which can be configured to form a quarter-split. So that this panel can be removed later, it is glued with polyethylene and lightly lubricated with a release agent (for example, PENTA-122-12).

In this case, it should be taken into account that the metal used can have a complex shape - this allows you to get additional profile stiffeners (Fig. 8). But at the same time, the task of gluing PPU liners is somewhat more complicated. The task of priming in this case, as a rule, is not worth it, since such a specialized profile is supplied already prepared for use in sandwich panels.

Metal with profile stiffening ribs can be used both on one side (Fig. 8), and on both sides.

The filling head is turned on and liquid is supplied to the second cavity. Upon completion, the head is moved to point 5 and the cycle repeats.

After the injection is completed (point 6 is reached), a decision should be made: continue pouring (if there are still molds) or flush. The bottom line is that after turning off the head, a little mixed composition remains in the chamber, therefore it can “start”. Therefore, when stopping (stopping injection) for 15 seconds, it is necessary to make a decision - either to continue filling (transition to the next section) or to flush. 0.6 of the start time is the guaranteed safe time of the mixed composition in the CG chamber, which can be removed at the beginning of the next injection or flushing.

Therefore, the transfer of the head from point 2 to point 3, from point 4 to point 5 should be carried out in no more than 15 seconds.

In order to ensure smooth pouring of the panels, it is optimal to have a conveyor when several molds are installed on it, continuously moving under the head. In this case, the speed of the conveyor should be 1750mm / 20 seconds, i.e. 5.26m/min. This speed will allow the conveyor to move the panel from point 1 to point 2 under the ZG in 20 (19) seconds.

In this case, it will be necessary to synchronize the operation of the conveyor with the operation of the pumping station, in other words, so that when the pumping station is turned off at 19 seconds (automatically, by remote control), the conveyor stops.

The standard control panel for the pouring machine is not intended for this, but if necessary, NPF NST can manufacture such a product for a specific customer.

If it is difficult or expensive to prepare a conveyor, then it is permissible to arrange the panels in a row, for example, three one after another, then after the injection into the first panel (point 6) is completed, a transition is made to the 2nd panel, etc.

NPF NST recommends limiting the number of injections to 9 flushes. after completion of pouring the third panel, the head should be rinsed. For this purpose, the head is transferred to the washing zone and the solvent is supplied to the mixing chamber for 15–20 s.

In the case of a conveyor, the head is suspended on a manipulator and, for washing, the “goose” boom is moved around the circumference to the side and the mixer is installed above the discharge tank, which is thus located in a circle whose radius is not greater than the length of the manipulator boom.

In the second case, it will be necessary to move the Pouring Head in a straight line along (above) the three molds ending in the discard container. It is necessary to ensure the movement of the mixer, for example, along a rail mounted under the ceiling at a speed of 0.526 m/min. Obviously, it will be difficult for a person to control such a movement, therefore, it is optimal to provide automatic movement of the CG along the rail and also synchronize the movement at the moments of the start and end of injection.

After the completion of the pouring, the holding stage follows, taking into account the dimensions and thickness of the products, it should be at least 30 minutes. Only after that it is permissible to proceed with the stripping of the panels, starting from the one that was filled earlier.

Then the panels are laid on the curing area, where they must be stored at a temperature of +18 to +24 for at least 36 hours.

The volume of finished products, the timing of the order are directly related to the number of forms and their standard sizes. The need for forms comes from the technological process.

Let's calculate the amount of formwork required to provide the given volumes (2150 sq.m.) of production. The area of one panel is 7.2 sq.m., respectively, 299 panels are needed in total.

Let us estimate the time of a full cycle for the manufacture of one panel.

The process steps associated with the use of molds are shown below.

Table 1

Technological operation	Time consumption
1. Apply primer to both sheets
2. Waiting for the solvent to evaporate from the primer
3. Applying glue and laying two foam bars on one sheet
4. Holding PPU-bars under the load (gluing)
5. Laying the cladding sheets in the form
6. Fixing and tightening the formwork
7. Pouring PPU into the mold (excluding stops between injections)
8. Exposure in the form
9. Disassembly of the mold
10. Removing the panel from the mold and transferring it to the curing area

NOTE
To reduce the number of technological operations, positions 3, 4 and 5 can be carried out when performing operation 6.

We exclude technological operations where the formwork is not directly involved.

table 2

Thus, during an 8-hour working day, one form allows you to carry out 7.16 removals, i.e. 7 panels per shift. The number of working days in a month, on average, is 22, respectively, one form will make it possible to produce 154 panels. Then, with the need for 299 panels per month, two formwork units are enough.

The cost of formwork is calculated individually for each Customer, based on the dimensions of the panel.

3. List and cost of the main equipment

3.1. Pumping station FOAM-20P75UM, capacity from 8 to 24l/min, has dimensions 1250x650x1000mm and weight 180kg. Motor power 2.2 kW, supply voltage 380V. The purpose of the pumping station is to take raw materials from the supply tanks, dose the components in a given ratio and feed them under pressure to the mixer. Performance management by means of an electronic frequency regulator. 11 options for the ratio of components "A" to "B": from 1 to 1 to 1 to 2, with a step of 0.1 along the isocyanate line (it is possible to change the ratio with a step of 0.1 and along the polyol line). Installation is executed on a wheeled frame - mobile. The machine is implemented on the principle of open architecture - the most convenient inspection, diagnostics and maintenance of components and assemblies is provided. The pumping station is supplied with all the necessary hoses and hoses, based on the installation of the pumping station and tanks within a radius of 5m from the manipulator. This model can only be used as a stationary pumping station for pouring foam.

3.2. Low-pressure mechanical mixer UM-ZG-016B, for pouring polyurethane foam composition. Dimensions 500x180x140mm, with a weight of 25kg. Motor power 0.55 kW, supply voltage 380V. The mixer is suspended on a manipulator in stationary conditions. Time of continuous work is not limited. It is completed with a hydropneumatic tank (GPB), which provides washing of the mixer with an open cycle. The necessary pipelines are supplied, based on the installation of the GPB within a radius of 5 m to the mixer.

3.3. Control panel UM-ZG-016B,. is designed for the convenience of controlling the polyurethane foam production process from a single unit (PENA-20P75UM UM-ZG-016B, connected to this console), automation and control of the injection of the composition, control of the washing process. The unit is mounted in close proximity to ZG-016 in such a way that the operator can control the mixer levers and remote control buttons without leaving the place.

3.4. Manipulator (allows you to move ZG-016 with a small hand effort around the circumference and up and down). The manipulator is rigidly attached to the floor. Manipulator height 2200mm, boom length 2500mm. The horizontal angle of movement of the crane beam of the manipulator, between the boundary positions is 120 degrees. The mixer, mounted on the crane beam of the manipulator, can move vertically up to 0.8 m. The initial suspension height is adjustable.

3.5. Two 227L feed tanks for raw materials (provided with filter elements) and a polyol mixing system. A recirculation system for both components is provided.

3.6. Compressor station K25M. Compressed air working pressure 4kg/cm2, consumption from 500 liters per minute. Air is supplied to the GPB for washing and purging the mixer at the end of work. It is allowed to use other sources of compressed air that provide the specified parameters in terms of productivity and pressure.

*The data is relevant for the winter of 2018

NOTE: if it is planned to fill according to the 2nd scheme (Fig. 8), then the manipulator should be excluded from the kit.

4. Requirements for the production room

To organize the production of polyurethane foam boards, a room is required, which should be divided into 5 sections: a warehouse for raw materials; section for preparation of facing sheets of panels; filling area; finished goods warehouse; compressor.

Raw material warehouse

With a given program for the production of 299 panels (with a total mass of PU foam insulation of 30.24 kg / panel), about 9 tons of raw materials will be required, which is equivalent to 36 standard 220-liter drums. Barrels are recommended to be placed only on one floor. For 1.5 sq.m. 4 barrels can be placed, totaling 13.5 sq.m. This area should be doubled in order to be able to maneuver and access each barrel, a total of 27 sq.m.

Section for preparation of facing sheets of panels

This site should be located in the immediate vicinity of the pouring site. Here it is necessary to have a moving table on which the facing sheet is laid (painted side down), then the primer is applied.

The table should optimally be able to rise - fall, and its surface is made of soft material, such as wood (smooth) or plastic, and equipped with rubberized rollers. This is necessary so that after priming it is possible to roll the sheet from the desktop to the shelf of the rack. If racks are not provided, then it will be necessary to provide for each sheet an area at least corresponding to the sheet area. The distance between the shelves of the rack is 0.4 ... 0.6 m. That. with a rack height of 2.4m, it is possible to place up to 6 sheets.
The operating time of the table for applying the primer to 1 sheet is 6 minutes, another 4 minutes to transfer the sheet to the rack. In total, 1 table will allow you to prepare 6 sheets per month. The minimum exposure time of one sheet on the rack after priming is 180 minutes.

Then, with a daily production rate of 13.6 panels (rounded to the nearest integer, 14), it is necessary to have 28 prepared (primed) facing sheets at the beginning of each working day. Then you need 5 racks, 4 of which will have 24 sheets and one will have 4.
Five racks will occupy an area (excluding aisles) of 36 sq.m. Considering a small release program, one desktop is sufficient. To coat 28 sheets, it will need to be used for 4 hours. Table area 7.2 sq.m.
The racks should be correctly positioned in one line so that the table can move along them on the rails. Accordingly, the area for moving the table is identical to the area of the racks.
That. the approximate area of the area for preparing facing panels is 72 sq.m.

Pour area

In this section, a filling machine, a manipulator (other arrangement for ensuring the movement of the head), a container for discharging the flushing liquid are mounted.

Also, the room must be equipped with a supply and exhaust ventilation system that provides 10-fold air exchange per hour. The air temperature at the pouring area is +20…+220 °С.

Based on the previously determined need for formwork, it is known that 2 units are needed. The placement is consistent, respectively, the length of the pouring section must be at least 15 m (see Fig. 10), at least 4 meters wide (space will be required when laying the sheets into the formwork and when removing them). Total 60 sq.m.
At the pouring site, it is necessary to provide a place for temporary exposure of the manufactured plates (at least 8 hours at a temperature not lower than +200 ° C) and means for monitoring the quality of products. In this case, there is no need for racks, the panels can be stacked on top of each other. With a laying height of 1.5 m (to ensure ease of removal), we have 10 panels on an area of 7.2 sq.m., so 14.4 sq.m. will be required to accommodate 14 panels. In this case, the laying height is recommended to be halved. To ensure the convenience of processing the panels, the area for time exposure should also be doubled.

In total, the total area of the pouring area is 90 sq.m.

Finished goods warehouse

The monthly requirement for panels is 299 pieces. It is unlikely that you need to ship them all at the same time. Let's assume that the shipment is carried out once a week, respectively, the area of the warehouse should allow placing up to 75 panels there. With a laying height of 1.5 m, 54 sq.m. It is also recommended to provide for a small excess of free space - up to 40%, in order to ensure convenience in the processing (warehousing, shipment) of panels, as well as to have a small reserve for additional placement of products. Total 76 sq.m.

Compressor

A small room (preferably isolated), no more than 4m2 or a spacious wooden box where the compressor is placed. This room should be ventilated from time to time.
Total, the total need for space: 27 + 72 + 90 + 76 + 4 = 269 sq.m.

5. Calculation of costs for primer, glue, raw materials, solvent.

Let's calculate the required amount of primer, glue, raw materials, lubricants and solvents in relation to the task under consideration (this calculation does not take into account the cost of metal - panel facing sheets).

Primer ADV23

Price 117 rubles / kg, consumption 150300gr. per sq.m. Monthly requirement: 299 x 2 x 7.2 x 0.3 = 1291.68 kg, total primer consumption for 151126.56 rubles.

Raw materials - system "A" + "B"

The price is 125 rubles / kg, the consumption per panel is 30.24 kg (including both filling and PPU inserts). Monthly requirement 299 x 30.24 x 85 RUB 1130220.00

NOTE: the cost of 1 kg of raw materials in Russia (as of June 2015) varies from 110 to 130 rubles.

Wash (solvent)

Based on the production program, it is supposed to carry out 149 cycles with pouring 2 panels (injection - transition - injection - transition - injection - transition to the 2nd panel injection - transition - injection - transition - injection - transition to the dump tank - flushing) and 1 cycle with one panel filling. That. it is supposed to flush the Filling Head 150 times.
Let's bring together the costs described above and determine the cost of one product and the total need for funds for the production of the required volume of panels (299 pieces 6x1.2x0.1m).

In total, expenses (without metal, electricity, wages and other expenses) for 1 panel 6x1.2x0.1 with a PPU density of 45 kg / m3 will amount to 4324 rubles. 16 kop.

Specialists of NPF "N.S.T." will help you calculate the cost of your order, help you choose the most optimal model of equipment, the brand of raw materials that is most effective for solving your problem, and also advise you on any issues of the technology for producing polyurethane foam by pouring.

Foam rubber has long been known as a durable material for the manufacture of elastic products. Existing enterprises in Russia are not able to fully meet the demand for this material on the domestic market of goods. Opening a mini foam rubber production plant in Russia will be quite beneficial for both those who are taking their first steps in entrepreneurship and businessmen with significant experience and seniority. Considering the fact that imported foam is much more expensive than domestic, competition with manufacturers from other countries is not an acute problem. In addition, calculations show that the production and sale of foam rubber will not require large initial investments from the entrepreneur.

Technology and equipment of foam production

If we consider the manufacture of foam rubber from the point of view of the technical equipment of production and the availability of raw materials, then a rather complicated picture is built. The fact is that each technological operation of the foam cycle is performed on its own separate equipment. And each stage of production requires careful control of the product's compliance with existing standards, only in this case the end result of the process will be high-quality commercial products.

The foam rubber production technology can be represented as the following industrial algorithm:

creation of a raw composition and loading it into the hopper of the foaming machine with continuous mixing;
filling the resulting solution with special folding forms;
providing a chemical reaction of the interaction of the components of the mixture before filling the foaming composition of the forms to the upper edge;
cooling of the material at a given temperature for 3 days;
cutting foam rubber in the form of sheet material into specified formats;
supply of finished goods to the warehouse.

An important role in obtaining high-quality material is played by the exact observance of the dosage in the reacting mixture of all components for foam rubber. There can be no errors here, everything must correspond terms of reference up to a gram, and the weighing process should be carried out on a scale with a very small error. At present, only high-precision electronic scales can cope with this task.

It is known that each large enterprise for the production of foam rubber uses its own technological features, their exact recipes and ratios of components. But the content of such substances as polyol and polyisocyanate in the initial mixture should be unchanged everywhere. The difference in production methods lies only in the number of secondary components that make up the mixture.

Since in technological scheme production of foam rubber provides for the flow of complex chemical reactions, then labor protection requirements for workers must be strictly observed there. This also applies to the air temperature of 18 ˚C, and ventilation capable of removing all harmful gases from the operating personnel area. It is necessary to take a very responsible approach to the work of the workshop's treatment facilities, which should provide reliable protection of the atmosphere from significant pollution.

For the plant to work with the manufacture of only high-quality goods, it is necessary to include an experienced technologist in the staff of its employees, who will be able to monitor the correctness of the production cycle at all its stages. He will be required to monitor compliance with the recipe and control both the feedstock for the foam rubber and the intermediate compositions of the working mixture. All these parameters are precisely regulated by state standards of the Russian Federation.

When buying equipment, the main decision is a semi-automated complex or a fully automated one? Of course, the automatic line is advantageous in that its operation does not require numerous maintenance personnel, and the quality of the manufactured goods does not depend on the variable human factor. But, on the other hand, the cost of these types of equipment is so different that sometimes a more profitable option is to install a semi-automatic complex at the enterprise and hire an increased staff. The final decision on the choice of a foam rubber production line is made by the businessman himself, comparing his future expenses and income.

The cheapest completeness of the purchase of equipment for the production of foam rubber should contain the following machines and units:

equipment for dosing mixture components;
foaming apparatus;
thermal chamber;
block forms;
foam rubber cutting machine;
apparatus for grinding primary production waste;
packaging machine.

The last two positions are necessary in the case of organizing production on a large scale, with the expectation of a large capacity of the purchased equipment.

The price of any equipment is largely determined by whether the machines will be purchased separately or as a complete production line. For the most part, entrepreneurs opt for a ready-made line of equipment, since here all devices are prepared in advance for interaction, which allows them to avoid possible overloads and breakdowns during their operation.

Foam rubber machine with a production capacity of 12 cu. meters of sheet material per working day is currently estimated by equipment suppliers at 600 thousand rubles. This is considered the minimum amount of capital investment in production, but with such productivity, the income of the enterprise will be quite modest. To buy a more productive line of equipment that is capable of producing up to 30 cubic meters per shift. meters of production, an amount of at least one and a half million rubles will be required. But it is precisely this performance that can be optimal for obtaining high profit enterprise.

There are now enough more productive lines for the production of furniture foam rubber on the equipment market, but for starting a business with a yet-to-be-established mechanism for marketing products, this option is not appropriate in economic terms.

We should not forget about the production of recycled foam rubber. Having skillfully organized waste collection, experienced entrepreneurs install equipment for the production of secondary foam rubber in their workshops. This makes it possible to obtain cheaper products, which play an important role in the struggle for the commodity market.

About product sales and profitability

The very process of organizing any production in our country is not very complicated. It is more difficult then to establish reliable sales of finished products by building relationships with representatives of the wholesale market. After all, it is wholesale buyers who are able to bring a large income to the enterprise. This all leads to the right idea that the distribution channels for your product need to be thought out at the stage of business design, and not when the warehouses are filled with finished products. Only operational work on the sale of foam rubber can lead to payback in the shortest possible time starting investments and a significant net profit.

Potential buyers of sheet foam rubber are:

furniture enterprises;
construction companies and trade networks;
toy factories;
manufacturers of high quality audio equipment;
footwear industry.

Considering such a large number of industries interested in purchasing foam rubber, there should be no downtime in the equipment of any newly organized workshop. It is only important that the prices offered to customers and the quality of products are attractive to them in the market of competing enterprises of a similar profile.

Making an analysis of the product sales market and studying the possibilities of competitors, you will have to join an active advertising campaign for the sale of foam rubber for upholstered furniture, which primarily includes high-quality foam rubber with an adhesive layer.

Speaking about the profitability of the business in the production of foam rubber, the main thing here is the competent organization of the business. With some effort and the ability to find the right contacts, the payback of starting investments in the business comes quite quickly. It is estimated that the registration of entrepreneurship, the purchase of equipment and raw materials, the rental of premises - everything takes on average up to 2.5 million rubles. This is an impressive figure of expenses, which can be reduced only by installing not new, but used equipment in the workshop.

But you should not save on raw materials. All raw material supplies should be made only from reliable customers, only this can allow the company to produce high quality products and maintain its customer base. Usually after a year active work the initial investment in the production of foam rubber pays off, and the company begins to give the desired profit to its founder. Namely, profit is the main goal of any business, any production.

The production of foam rubber (elastic polyurethane foam) is a technologically simple process. This fact should be considered as a business idea for small investments. The main thing is to adhere to all safety standards in production. In fact, foam can be made in elementary laboratory conditions in a chemistry lesson. Today we all meet with foam rubber every day in its various manifestations. Upholstered furniture is covered with foam rubber, soundproofing is done, doors are insulated, etc. Elastic polyurethane foam (PPU) is found in our kitchen, and in the bathroom, and in the children's room, and in our furniture, and in many other things that a person faces throughout the day. Based on the fact that foam rubber is in great demand, you should think about its production. Moreover, the price of the minimum configuration of equipment is quite affordable for small businesses.

Equipment for the production of foam rubber

Foam rubber is produced using two production technologies:

Continuous production technology.
Periodic production technology.

The batch production method of foam rubber is simpler, which is why it is ideal for small business and newbies in the field. At the same time, the equipment for the periodic method of manufacturing is somewhat cheaper, and this method does not require special training. The equipment can be installed by a company that sells and installs working equipment. The services of such a company usually do not exceed 10% of the cost of the machines themselves. Minimum set of equipment:

Foaming apparatus.
Thermal camera.
Foam cutting machine.
Dosing device.
Block forms.

Additionally, you can purchase a crushing machine (it will allow production to be waste-free) as well as a packaging machine (for twisting foam sheets into rolls and wrapping them in plastic wrap). The minimum set of equipment can be purchased from $7,000.

Periodic technology in the production of flexible polyurethane foam

The batch production technology is as follows:

In a mixing tank of the required volume, a polyurethane foam mixture (water, isocyanate, polyol and other standard components) is poured in a certain amount.
Depending on what type and with what characteristics the foam rubber should be obtained, a strict recipe for mixing the components is observed. Although they can be purchased already dosed for each type of flexible polyurethane. Prepared components are slightly more expensive, but greatly simplify preparation before production. Depending on the proportions of the components, during the reaction, cells of distinctive sizes and shapes are formed in the foam rubber. The smaller the cells, but the larger the walls of the cavities, the better it resists loads. For example, furniture elastic polyurethane at break must withstand 270 Newtons. Such high-quality foam rubber will be elastic and quickly restores its shape. On the other hand, it requires more consumables and therefore has a higher cost.
The mixture is stirred in special equipment. The mixed mixture is poured into a special block mold. In this block mold, the foaming process takes place. After that, the resulting foam block is kept in shape for some more time. After the allotted time has elapsed, the side walls are opened in the block form and the finished foam block is removed. But, in order to make the foam rubber fully ready, it is moved to a separate room, where it will be kept for at least another day. And only after that, the foam blocks are cut into sheets of the required thickness, which are mainly used in the furniture industry.

This production technology does not require large financial costs for equipment and personnel. That is why it is suitable for small businesses.

Profitability of a business idea

Let's calculate the profitability using the example of one standard portion of foam rubber produced by a batch production method. To get one block (2000x1000x1100 mm) of the finished product, you need to purchase a six-component portion of raw materials 50 kg (in the kit, all the necessary components are already in exact proportions) = $ 140. After the production process, we get a block of foam rubber at the output, which should be cut into foam rubber sheets (2000x1000x10mm). The retail price of one such sheet is $2. We should get at least 100 sheets (because 2 of them will most likely be defective).

And that $2 x 100 - $140 = $60 profit. With a large production facility, the $7,000 line can produce 10 tons of flexible polyurethane per month.

Properties in quality foam rubber

By itself, the foam rubber is quite dense and light material. It, like all other types of polyurethane foam, has a porous structure and consists mainly of air bubbles (up to 90% by volume).

The main parameters for assessing the quality of foam rubber:

Strength of flexible polyurethane foam. At this stage, the level of ultimate strength is checked, which is determined by the level of elongation at break.
Elasticity. This indicator directly depends on the rigidity of the elastic foam, the greater the rigidity, the less elasticity. Such a quality item is checked by measuring the height of the "jump" of the ball that falls on the sample.
Rigidity. This indicator is checked by compressing the sample of the product by 40% of the total length of the sample. The stiffness depends on the pore size, the larger the size of the balloons, the higher the stiffness.
The density level of PPU is measured in kg / cubic meter. And this is the main indicator of quality.
Percentage of permanent deformation. This parameter indicates the ability of flexible polyurethane foam to maintain its original performance throughout the entire service life. It is measured by squeezing a polyurethane foam sample for a certain amount of time, and setting the percentage of the original values.
Comfortable elastic foam. This parameter distinguishes furniture foam rubber marking HR.

Based on these basic evaluation parameters, it is divided into three main types:

Standard (ST).
Highly elastic (HR).
Rigid polyurethane foam (HL).

In the furniture industry, mainly EPPU with the HR marking is used. With the ST marking, they are also used for the production of furniture, but only for those that will not be subjected to heavy loads.

Sales of manufactured products

Still, the main consumers of flexible polyurethane foam are furniture manufacturers. Therefore, before starting such a business, it is necessary to consider ways to market the products. But do not forget also about the manufacturers of soft toys, household companies (production of various types of sponges), acoustics and many other areas of activity. Elastic polyurethane foam has always been a sold type of consumables, so it will be easy to sell.

Today, we can say with some certainty that the market for the production of foam rubber is quite competitive. Therefore, you should not count on large factories and enterprises as partner-consumers. But if you have small furniture enterprises in your city, you may well compete with large competitors.

Manufacturing Precautions

The elastic polyurethane foam itself is safe for humans, therefore it is allowed to produce upholstered furniture from it. Although the finished foam rubber itself is not hazardous to health and meets all hygiene standards, the process of its production requires strict adherence to industrial precautions. Chemical components in contact with mucous membranes in humans can cause irritation. Isocyanate (mandatory component) has Negative influence on the skin and respiratory tract. Therefore, the operator must wear a respirator, goggles and a protective suit. It is also necessary to equip the production room with supply and exhaust ventilation, which is designed in accordance with safety standards. This will get rid of the bad smell. And all harmful substances decompose under the influence of air into elements that are absolutely safe for humans. It is forbidden to pour non-recycled components into the sewer, as this affects the pollution of the environment. Unrecycled raw materials should be safely disposed of.

planning to start own business in the field of production, it is better to give preference to the production of products that are in high demand, independent of the season and the economic situation in the country. One of such solutions is the production of foam rubber (elastic polyurethane foam, PPU) in Russia. Of course, this area (as well as) requires large investments, but with a competent approach, all costs will pay for themselves very quickly.

Production of foam rubber in Russia

Today, the production of foam rubber in Russia is going through hard times. Almost all raw materials, apart from oil and gas, are purchased abroad. The same applies to foam rubber, because domestic volumes of its production cannot fully satisfy the existing demand.

In this regard, the question arises: why not increase the production of polyurethane foam in Russia? After all, with the existing demand for foam rubber, its production will bring very tangible benefits to the manufacturer, especially since the quality of Russian products is in no way inferior to imported ones, and transportation costs are commensurately lower, which allows domestic manufacturers to offer their goods at more attractive prices.

Strengths and weaknesses of the business

Foam rubber has been used both for domestic and industrial purposes for many decades. Although the market today is teeming with modern materials with similar characteristics, flexible polyurethane foam is still very popular among wholesale customers. This is precisely the main advantage for the entrepreneur.

The production and sale of polyurethane foam in Russia is still very poorly developed, which gives novice businessmen a high chance of an early payback. If you enter the market with a quality product, you can bypass any competitors.

The main difficulty in business is the equipment of the premises. The production of flexible polyurethane foam is a hazardous process, and therefore all workshops must be equipped with powerful ventilation, which, in turn, implies significant costs. You will need permission from the supervisory authorities to conduct business. An entrepreneur must strictly observe working conditions, control the amount of harmful emissions into the atmosphere, and also be prepared for constant inspections by fire authorities, environmental inspectorates and sanitary services.

Advice: The best time to start production is early spring (March to April). It was at this time that furniture factories began to actively purchase raw materials, which means that it would be much easier to find buyers for their products.

What industries does foam rubber cover?

PPU is a reliable softening and supporting material used for thermal insulation and giving elasticity to things. The main niche for the sale of polyurethane foam is occupied by the following industries:

enterprises producing fragile and mechanically affected products that need a soft lining to prevent their deformation and breaking;
furniture firms using foam rubber for stuffing armchairs, sofas, etc.;
construction companies that use polyurethane foam for heat, vibration and sound insulation.

Potential buyers purchasing relatively small amounts of foam rubber include:

shoe manufacturers using this material in the manufacture of insoles;
enterprises producing audio equipment - for the manufacture of headphones and audio speakers;
building materials stores.

When opening your own production of foam rubber in Russia, it is necessary to correlate the planned volume of manufactured products with the actual expected volume of its sales. At the same time, close proximity should be taken into account. potential clients. If the plans are to supply material outside the region, then first you need to assess the competitiveness of the final cost of the transported foam rubber, taking into account the costs of its delivery.

Production technology

The manufacture of foam rubber is considered an environmentally hazardous, and sometimes harmful to health, production. After all, this process uses polyol, aromatic isocyanates, some types of catalysts and foam stabilizers.

Some of these "ingredients" are toxic when evaporated, but when in contact with water and air, they decompose into non-hazardous substances. It is for this reason that the production workshop must have running water and good ventilation, and the working staff must have respirators.

The technology for the production of polyurethane foam depends on the method - batch and continuous. The first option is most often applicable to small (up to 500 tons/year) and medium-sized (500-2000 tons/year) enterprises. The continuous method is appropriate for large enterprises engaged in the production of large volumes (over 2000 tons / year).

The "averaged" production scheme is as follows:

acceptance and accurate dosing of raw materials;
mixing "ingredients" and their subsequent foaming;
pouring the solution into special block molds with folding walls;
exposure of foam rubber (up to ¼ hour), in which, as a result of a chemical reaction, the mixture rises to the upper edges of the mold;
block cooling;
cutting foam rubber into sheets of the desired geometry (after three days);
warehousing.

During the production of polyurethane foam, waste is generated. They can be put on sale, or you can organize the production of recycled foam rubber. This technology consists in foaming foam rubber crumbs and scraps with special glue and in their further crimping. The finished material is characterized by increased strength, service life and sound insulation. Acoustic foam rubber and mats for gyms are made in a similar way.

Technical equipment

The manufacture of foam rubber, as well as, requires a complex technical equipment. The purchase of equipment is considered the most expensive item in the budget. To start the workshop, you need to purchase the following machines:

dosing equipment;
foaming machine;
thermal camera;
forms for solidification of the mass;
cutting machine;
plant for grinding waste;
packing machine.

It is very difficult to independently assemble a line consisting of individual machines. Therefore, it is easier for novice businessmen to buy a ready-to-work line. The cost will depend on the power of the machines. can be equipped with a low capacity line capable of producing up to 12 cm³ of material per shift. This equipment will cost the entrepreneur 400,000 rubles. If you buy machines of greater power (up to 50 m³), you will have to spend at least 2,000,000 rubles. To the above costs, it is also worth adding the services of a commissioning wizard for the purchased equipment. Of course, you can set up the production line on your own, but for this you need to be well versed in the specifics of its work.

If the starting capital is limited, then you can save money by buying a used line. The cost of used devices is much lower. And if you can find a reliable seller, then such equipment will last a very long time.

Workshop room

Foam rubber factories are best located in vacant premises on the outskirts of the city. Firstly, the rent here is much lower, and secondly, the requirements for environmental safety are more loyal. All these factors only play into the hands of a businessman.

Basic requirements regarding industrial premises comes down to two criteria:

ceiling height - it should be at least three meters;
maintaining the air temperature at 18°C (not less!). If in the shop for pouring the foamed mass into molds it falls below this limit, then the production of foam rubber will be impossible due to the lack of the necessary chemical reaction.

The working area of the premises itself should be at least 200-250 m², taking into account the household room for workers and a small office for a technologist. The operation of the ventilation system must always be in good working order and be in the active phase. You will also need a 380 volt electrical wiring with grounding. To install band saws, you will need to build a small foundation.

For ease of transportation, it is necessary to provide for the presence of an adjacent territory. The larger it is, the higher the loading speed and the better the work of transport in general. Access roads must be equipped with special symbols - both drivers and staff will be easier to navigate in their work.

Staff

No more than ten employees will be required to start the production workshop. First of all, a chief technologist is needed, preferably a person with the education of a chemical technologist. At worst, one who has undergone specialized training and practice.

For service production line five workers are enough: three people for the pouring machine and two for the cutting machine. Also, you can not do without the help of several handymen. Their duties will include loading and unloading of raw materials and finished products. The presence of special education and qualifications for this category of workers is not required.

Development prospects

The production of flexible polyurethane foam has its own prospects, which are primarily associated with the manufacture of molded products. Similar products are used in the manufacture car seats and expensive furniture. It is also possible to establish additional production of household sponges, washcloths, rugs, fillers for children's toys, etc. without significant costs.

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With successfully established sales channels, in a year (and if you're lucky, a little earlier), the company will begin to make a profit. It is best to look for clients among furniture manufacturers, it is they who provide high demand and special profitability of this business idea. If things go uphill, then after a while it will be possible to think about.

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